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This sounds like a great project. I'd definitely go with the flaps to help seal the gap between car and trailer, making them from clear Coroplast to keep the lights visible. With gap sealers, the trailer front does not need careful rounding.
In boats, framless construction has become quite popular. You just cut out thin plywood to the shapes it would get trimmed to on a frame, and sew the panels together with wire. It takes a bit of propping up initially but after a few passes with the epoxy and fiberglass tape, and it is stronger than solid molded shapes. You can also do continuous 'glass for a super sandwich structure. see Stitch and Glue, or tack 'n' tape, etc.
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There is no excuse for a land vehicle to weigh more than its average payload.
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